Remanufacturing and Reverse Logistics: Waste to...

Remanufacturing and Reverse Logistics: Waste to

Recovery Vietnam Supply Chain Congress | October 18, 2011

Presented by:

Gopal R, Vice President

Transportation & Logistics Practice

Frost & Sullivan Asia Pacific

2

Agenda

WHY IS REMANUFACTURING CRITICAL?

HIGHLIGHTS ON EFFORTS IN REMANUFACTURING

REVERSE LOGISTICS: HOW DOES IT FIT?

OPPORTUNITIES FOR VIETNAM

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WHY IS REMANUFACTURING CRITICAL?

4

Potential for Remanufacturing

2010 Global manufacturing output = USD 10.1 Trillion

IN APAC, China alone make up USD 2.0 Trillion accounting for

approximately 20 percent of the 2010 global manufacturing output

Global remanufacturing output value not even 5 percent of global

manufacturing output

Sustainability issues in manufacturing…

opportunity for Remanufacturing

5

What we had done!

Extensive Mining Activities Landfill

Deforestation Air pollution

• 100 million units personal

computer sold in APAC

• 130 million units of

smartphones sold in APAC

• Rain forests being cut

down 100 acres per minute

6

Is our inputs to manufacturing sustainable?

Coal = ~ 7 billion Tonnes

Steel = ~ 1.3 billion Tonnes

Crude oil = ~ 30 billion Barrels

2010 world consumption of non renewable natural

resources

2010 world reserve for non renewable natural

resources

Coal = ~ 930 billion Tonnes

Crude oil = ~ 1350 billion Barrels

High

Consumption

Limited

Resources

Not

Sustainable

+

=

7

Facts to ponder…

• Every year we fill enough garbage trucks to form a line that would stretch from the

earth, halfway to the moon.

• Only two human-made structures on Earth are large enough to be seen from outer

space: the Great Wall of China and the Fresh Kills landfill, located on the western shore

of Staten Island!

• Raw materials saved by remanufacturing would fill 155,000 railroad cars forming a train

1,100 miles long.

• Energy savings by remanufacturing equals the electricity generated by 8 nuclear power

plants or 16 Million barrels of crude oil

8

Then, How?

We don’t have the liberty of infinite resources to sustain future growth at this pace…

9

Viable Solution: REMANUFACTURING

Viable Solution:

REMANUFACTURING

• Conserve natural resources

• Eliminate Landfill

• Save the forest and environment

• Second line of products for manufacturers

10

Global market demands and

governmental pressures

Pushing business to become

more sustainable

Legislation regarding

environmentally-friendly

products

Remanufacturing is becoming

more important than ever

Consumers and distributors are

seeking repair and service

options

good financial sense and high-

quality products

Remanufacturing: Path for Sustainability

Annual energy savings

resulting from

remanufacturing

activities worldwide:

120 trillion Btu’s, which

equals the electricity

generated by 8 nuclear

power plants, or 16 million

barrels of crude oil

Remanufacturing saves

over 80% of the energy that

would have been used to

produce a new part

Remanufactured

components are 40 – 60%

the cost of a new

component and can save

70% on materials during

production

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Benefits of Remanufacturing

Cost savings Raw material

conservation

Increased profits Landfill space

conservation

Enhanced reputation and

market value Air pollution reduction

Purchasing flexibility

Environmental Angle Business Angle

Energy conservation

The Benefits of Remanufacturing

12

HIGHLIGHTS ON EFFORTS IN REMANUFACTURING

13

What companies do in Remanufacturing?

I. TATA – Recon Engine

II. Aisin AW – Remanufactured A/T

III. Fuji Xerox – Remanufacturing

components

14

Reconditioned engines is a unique exchange scheme offered by Tata Motors Pvt

Ltd, in which, OE standard, high quality long blocks are provided in exchange of

used long blocks

What TATA Motors has done?

Reconditioned engines offers the following benefits:

• Genuine spare components

• Highest quality of aggregates and components

• Higher performance, comparable with new product

• An increased uptime of the vehicle, ensuring higher returns

• Attractive warranty and nationwide service support (backed by 6 months warranty)

• Wide range of reconditioned engines

Beside Engine, TATA also promotes Recon power steering, rack and pinion gear,

power steering pump and so on

15

What Aisin AW has done?

Remanufacturing automatic transmission at lower price for repair and

replacement of models already in service

• The company started the remanufacturing business in 1969

• During 1979 -1980, company started remanufacturing of A T for Toyota

models

• Expand the use of returnable container

• Remanufacturing project for hybrid system

• Promoting initiatives to recover discarded parts

Company contributes to environment conservation through its remanufacturing

program. In 2009, The company had remanufactured 13,000 units of A T in Japan

16

What Fuji-Xerox has done?

The company installs all remanufactured components in all products without

distinction between new and remanufactured products

• Demand for remanufactured products is not restricted by consumers product selection

• Achieve 99.9 percent resource recycling rate from products in Japan, 99.8 percent

from Asia Pacific

• Reusing waste toner saves several million dollars in raw-material costs each year.

• Equipment remanufacture and the reuse and recycling of parts prevent millions of

pounds of waste from entering landfills each year.

Source: Fuji

Xerox 2010

sustainability

report

17

Remanufacturing: Select Industry Examples

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Automotive Sector (e.g. spare parts, tires, alternators, starter motors, engines)

• BMW’s recycling and remanufacturing campaigns has shown that the cost of a

remanufactured engine of BMW account for 50-80% of a new one.

• During this process, 94% of the old engines are repaired, 5.5% of them dissolved regeneration

and only 0.5% is dumped in landfills.

• Since 1947, Volkswagen has managed to recover 7.48 million units of original engines

remanufactured.

• This figure is equivalent of saving 337,366 tons of steel (enough to build 49 Eiffel Towers and

161 golden gate bridges).

• CO2 were reduced by 572,220 tons, sulfur dioxide emissions reduced by 569 tons, and nitrous

oxides emissions reduction of 662 tons

Healthcare (e.g. Medical Devices)

• Ascent leads in the remanufacturing of medical devices in the US, its hospital partners have

realized hundreds of millions of dollars in cost savings through the use of medical device

remanufacturing programs.

• On a per-hospital basis, some hospitals saved more than $600,000 per year. Ascent’s

programs also helped customers reduce their environmental footprint by diverting an estimated

5.3 million pounds of total waste from landfills.

18

Remanufacturing: Select Industry Examples

• 265 million HP print cartridges have been recycled since the Renew program began in 1991,

representing a weight of 343 million pounds.

• HP has also been recycling and refurbishing computer hardware since 1987, and collects

approximately 2.5 million hardware products each year that is refurbished, resold or donated.

Electronics (e.g. Computers, TV’s and Cameras)

• IBM processed nearly 100 million pounds product end of life equipment and material with

only 0.78% returned to landfills or incinerated.

• IBM Global Asset Recovery Services processed 88,512 metric tons of end-of-life product

and material through its de-manufacturing centers, resold or reused over 4.6 million machines and

processed an estimated 40,000 machines or 1.8 million pounds per week around the world

Imaging Industry (e.g. Copiers and Ink Cartridges)

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Regulation, Initiatives or Incentives for remanufacturing

Quality System Regulation (revision of Good Manufacturing Practices (GMP)) – To

define remanufacturing, ensure quality of remanufactured products and identify parties

responsible for remanufactured products

China certified manufacturing companies with pilot remanufacturing enterprise status to

acknowledge and encourage manufacturer involvement in remanufacturing industry

Government of China granted funds to further research into remanufacturing, enhance

the role of research institutions and companies in pushing forward technological

innovation in the remanufacturing sector

Regulation

Initiatives or Incentives

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REVERSE LOGISTICS: HOW DOES IT FIT?

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Need for reverse logistics - The core concept applies

Through choice of most profitable alternative:

• Reconditioning – when a product is cleaned

and repaired to return it to a “like new” state

• Refurbishing – similar to reconditioning,

except with perhaps more work involved in

repairing the product

• Remanufacturing – similar to refurbishing, but

requiring more extensive work; often requires

completely disassembling the product

• Resell – when a returned product may be sold

again as new

• Recycle – when a product is reduced to its

basic elements, which are reused – also

referred to as asset recovery

Plan, Implement and Control

Raw Materials

In-process Inventory

Finished Goods

Info

rmati

on

Point of Consumption

Point of Origin

Eff

icie

nt

an

d C

ost

Eff

ecti

ve F

low

PURPOSE

• Capture Value or Proper Disposal

22

Reverse logistics provide support (raw materials) to

remanufacturing

Reverse Logistics Remanufacturing

Make money from

waste

Provide Support

Create Opportunity

Save the

environment Sustainable solution

23

Reverse supply chain requirements can be organized at either

consumer or industry level by key industries

Textiles & Apparel

Food Processing

Life Sciences

Engineering Support

Machinery & Equipment

Petrochemical & Polymer

Basic Metals Consumer Plastics

Electrical and Electronics

Wood based Industry

Rubber Products

Transport Equipment

Reverse Supply Chain:

Consumer Level

Reverse Supply Chain:

Industry / OE Level

Reverse Supply Chain:

Hybrid

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Potential reverse logistics hubs / sourcing locations

Mobile Devices Printer /

Cartridge

Battery

Engines /

transport

equipments

China

Hong Kong

Singapore

Malaysia

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OPPORTUNITIES FOR VIETNAM?

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Strong growth trend of manufacturing industry with CAGR of 25 %

CAGR = 25%

Gro

wth

(%

)

Gross output of manufacturing industry in Vietnam

Indicates Vietnam as a strong and sustainable manufacturing source in the region

27

Transport equipment, electronics and electrical equipment are the

key industries for remanufacturing

Breakdown of manufacturing industry by gross output

Key industries

with

remanufacturing

potential in Asia

Pacific

28

Moving up value chain - Remanufacturing

1986 2007 2010

Transition of

Vietnam

Economy

Joined World

Trade

Organization

(WTO)

2020

Focus on

• Infrastructure development

• Human resources training

• Social-economic

development

Move up the value chain by not

only manufacturing quality

products at low cost

New Business Model -

Remanufacturing

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Opportunity to emerge as remanufacturing hub

China

Hong Kong

Malaysia

Vietnam can emerge as

remanufacturing hub due to

• Low manufacturing cost

• Strong and sustainable

manufacturing industry

• Strategic location surrounded

by major production and

logistics hubs

Singapore

Vietnam

30

Potential countries to source used core…

Transportation

Equipment

Electronics,

mobile

products

Printer /

Cartridge

Thailand

Thailand

Rem

an

ufa

ctu

rin

g

in

Vie

tna

m

Source of used products

Malaysia

Taiwan Malaysia Singapore

China

Malaysia Singapore

Taiwan

Indonesia

Indonesia Hong Kong

Hong Kong

China

China

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Remanufacturing hub for transportation equipment

Transportation

Equipment

As remanufacturing hub for transportation equipment such as

power steering, rack and pinion gear, power steering pump

and so on

Used parts collected from other

countries Disassembly of used parts

Cleaning and surface treatment of

subparts

Reconditioning Reassembly Final Testing Used alternator (Left)

Remanufacturer alternator (Right)

Source: Shin – Etsu Denso Co. Ltd.

32

Collected and remanufactured

Printer /

Cartridge

Developed robust reverse supply chain to collect used

cartridge, printer, battery and mobile devices for

remanufacturing Electronics,

mobile

products

Support by Key Manufacturers: Fuji-Xerox,

GE and Nokia

Raw materials from

other countries

Remanufacturing in Vietnam

Remanufactured

products

To be distributed

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What needs to be done?

Efficient

reverse

supply chain

Government

incentive

Increase

awareness in

remanufacturing

34

ABOUT FROST & SULLIVAN

35

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